Corrosion-resistant Steel Plates

Transcription

1 Plate Corrosion-resistant Steel Plates Notice: While every effort has been made to ensure the accuracy of the information contained within this publication, the use of the information is at the reader s risk and no warranty is implied or expressed by Nippon Steel & Sumitomo Metal Corporation with respect to the use of the information contained herein. The information in this publication is subject to change or modification without notice. Please contact the Nippon Steel & Sumitomo Metal Corporation office for the latest information.please refrain from unauthorized reproduction or copying of the contents of this publication. The names of our products and services shown in this publication are trademarks or registered trademarks of Nippon Steel & Sumitomo Metal Corporation, affiliated companies, or third parties granting rights to Nippon Steel & Sumitomo Metal Corporation or affiliated companies. Other product or service names shown may be trademarks or registered trademarks of their respective owners Marunouchi, Chiyoda-ku,Tokyo Japan Tel: Fax: Corrosion-resistant Steel Plates A11en_1_2179f 217 NIPPON STEEL & SUMITOMO METAL CORPORATION

2 Corrosion (rusting) We are surrounded every day by many steel objects in diverse shapes that are used for various purposes. A massive amount of steel is used in large structures (bridges, ships, vehicles, and buildings), oil well casings and pipelines, and automobiles and electric appliances. However, steel is intrinsically corrosive (rusty) if corrosion prevention measures are not employed. Rusty!! methods There are roughly four corrosion protection methods: Coating, the use of special steel stock (with corrosion-resistant materials), the use of electricity, and environmental improvement. Each of them has its own characteristics such as the anti-corrosion effect, cost, workability, maintainability, etc., and is used on a case-by-case basis. using electricity by coating You can rely on us! through environmental improvement using special steel stock Corrosion-resistant Steel Plates Corrosion-resistant Steel Plates Corrosion-resistant Steel Plates are used as special steel stock for corrosion protection. They are steel materials with corrosion resistance improved by adding anti-corrosion elements (Cr, Cu, Ni, etc.) in an amount that most suits the environment in which the steel is used. Weather-proof steel, seawater-resistant steel, sulfate-resistant steel, etc., are available in accordance with the environment from which the object in need of an anti-corrosion measure is protected. NSSMC Corrosion-resistant Steel Plate series The Corrosion-resistant Steel Plates of NSSMC have been developed as a shield that protects the sustainability of steel structures from corrosion in both acid and neutral regions, atmospheric corrosion, dew-point corrosion, and seawater corrosion produced by various factors in diverse environments. By selecting the Corrosion-resistant Steel Plate most suitable to the need that may vary according to the circumstances, the construction period and cost for maintenance can be reduced, effecting a significant life-cycle cost reduction. Acid region corrosion environments Sulfuric acid/hydrochloric acid dew-point corrosion Exhaust gas treatment equipment at waste incineration facilities: S-TEN TM 1& 2 Boiler air preheaters at thermal power generation facilities: S-TEN TM 1& 2 Corrosion Factors (environments) and NSSMC Corrosion-resistant Steel Plates Atmospheric/salt corrosion (coastal areas Uncoated bridges and structures: NAW-TEN TM 12,15 Coated bridges and cranes: CORSPACE TM Neutral region corrosion environments Seawater corrosion Crude oil tankers, cargo oil pipes, ballast pipes, floodgates: MARILOY TM S-TEN TM P2 NSGP TM P3 NAW-TEN TM CORSPACE TM ARU-TEN TM MARILOY TM P4 P5 P6 P7 Acid corrosion Bottom plates and upper decks of crude oil tankers: NSGP TM 1& 2 Atmospheric/salt corrosion Building exteriors, bridges, towers in inland areas: COR-TEN TM Floors/walls designing: VINCOR TM, CORQ TM Indoor environments/indoor vacuum containers/precision machines: ARU-TEN TM COR-TEN TM P8 VINCOR TM, CORQ TM P9 Acidic Neutral Alkaline

3 Acid corrosion Acid corrosion Sulfuric-acid/Hydrochloric-acid Dew-point Resistant Steel S-TEN TM NSSMC s hot-rolled steel plates comply with JIS G 316. S-TEN1SM4A S-TEN2SM49A High Corrosion-resistant Steel for Crude Oil Tankers NSGP TM -1&2 Approved by classification societies as a corrosion-resistant steel product for cargo oil tanks. Sulfuric acid dew-point corrosion due to fossil fuel-derived sulfur oxides. Hydrochloric acid dew-point corrosion derived from dioxins. Delivers superior performance against sulfuric acid/hydrochloric acid dew-point corrosion in smoke control systems of coal-fired boilers, waste incineration facilities, etc. Deep pits are formed in tank bottom plates. All surfaces of tanks under the upper deck corrode. Taking corrosion prevention measures for tanks was made obligatory in 213. The frequency of pit forming in the bottom plate decreases to 1/15 of conventional steel. The corrosion amount under the upper deck decreases to approx. 6% of conventional steel. By eliminating the coating process, a reduction in construction cost and life-cycle cost can be achieved. Hydrochloric acid dew-point corrosion of an inner cylinder of a chimney Pitting corrosion on the tank bottom plate of a crude oil tanker Mechanism of sulfuric acid/ Exhaust gas temperature: 18 C Hydrochloric acid dew-point corrosion occurs! hydrochloric acid dew-point corrosion taking place in the smoke control system of a waste incineration facility Exhaust gas temperature: 1315 C Exhaust gas is quenched to lower the temperature for dioxin reduction 136 C Sulfuric acid dew-point corrosion occurs! 72 C Under the condition of exhaust gas consisting of SO3: 3 ppm, HCl: 3 ppm, H2O: 3% Sulfuric acid immersion test results in a vapor-liquid equilibrium state of sulfuric acid and the water system Under the conditions of 7 C and H2SO4 at 5%, S-TEN shows corrosion resistance of approx. five times that of conventional steel and approx. 1 times that of stainless steel. 25 (6 hours) SUS 43 9 SUS 41 8 SUS 34 7 SS 4 6 SUS COR-TEN O Temperature 2 4 H2SO4 Concentration 1 2 Corrosion rate (mg/cm 2 /hr) High Steel plate surface temperature Low Conventional smoke control system 6 4 Latest smoke control system Hydrochloric acid coagulation Has excellent corrosion resistance in a strong acid environment at low ph levels. S-TEN 1 S-TEN Sulfuric acid coagulation 14 8 % Superior corrosion resistance is confirmed through a sulfuric acid immersion test. S-TEN TM is NSSMC s original sulfuric/hydrochloric-acid dew-point resistant steel that has a long-term and excellent track record. More economical than stainless steel. It offers a wide variety of types including hot-rolled and cold-rolled steel plates, steel pipes, and weld materials. High accessibility is secured by steel product wholesalers that constantly have the product in stock. Comparable strength, workability, and weldability with those of conventional steel. Ichimura Prize in Industry for Excellent Achievement (FY26) Award for excellence of Nikkei Excellent Products & Services Award (FY23) Real machine test results The life extension effect of approx. five times that of conventional steel is confirmed in an air preheater of the steel pipe type for heavy oil-fired boilers. Test subject Air preheater of the steel pipe type for heavy oil-fired boilers at electric utility company K Test piece installation point Used at the front of re-heater low-temperature tanks of the air preheater Exhaust gas temperature Sulfuric acid dew point C 13 C Gas composition SOx H2O 36ppm Approx. 1% Test time period 4,88 hours Metal temperature 7 8 C Start and stop 35 cycles Steel type Measurement value of reduced wall thickness Estimated annual due to corrosion (mm/4,88 hours) corrosion amount Maximum Average (mm/year) S-TEN 1 SS Test conditions Test results Has an excellent track record mainly in the area of smoke control systems. The effect is confirmed in a real machine exposure test as well. Positions to which NSGP-1 and 2 were applied Number of pits NSGP-1 Upper deck above the crude oil tanks Conventional steel Maximum number of pits formed Decreased to approx. 25 NSGP-1 Number of pits Average number of pits formed Decreased to approx Conventional steel 13 NSGP-1 NSGP-2 Bottom plate of crude oil tanks Produces corrosion reduction effect for COTs (cargo oil tank) of crude oil tankers. Comparison of pitting corrosion (4 mm deep or more) occurrence frequency after a lapse of five (NSGP-1) after a lapse of two and a half NSGP-1 after a lapse of two and a half In ships that use conventional steel for tanks for five, up to 1,3 pits of at least 4mm-deep per tank are formed from corrosion. In those that use NSGP-1 for tanks, the number of pits formed from corrosion has reduced to approx. 1/5 of those with conventional steel, or to approx. 1/15 on average. NSGP-1 significantly delays the progress of pitting deep into bottom plates (pitting corrosion) attributable to salt water contained in crude oil. NSGP-2 significantly delays the corrosion expansion over all surfaces of tanks attributable to H2S contained in crude oil, exhaust gas charged into tanks to prevent explosion, and dew condensation caused by the temperature gap between day and night. The corrosion resistance that is produced by the alloy components does not vary contrary to products with corrosion resistance provided by coating. Welding materials for exclusive use with enhanced corrosion resistance are also offered. Ichimura Prize in Industry for Distinguished Achievement (FY21) Special Prize of Monozukuri Nippon Grand Award (FY211) Award for excellence of Nikkei Excellent Products & Services Award (FY27) Transition of the corrosion amount and comparison (NSGP-2) The high performance of NSGP-1 and 2 has been confirmed in actual ships to which they have been applied. Plate thickness (mm) Significantly suppresses the generation of pits and corrosion on all surfaces of crude oil tanks. Initial stage After 25 (estimated) Corrosion amount Initial stage Decreased to approx. 6% NSGP-2 After 25 (estimated) Corrosion amount after a lapse of two and a half NSGP-2 after a lapse of two and a half When the corrosion amount after 25 is estimated from the results of the use of conventional steel and NSGP-2 in actual ships for eight, it can be predicted that the corrosion amount of NSGP-2 can be reduced to approx. 6% of the corrosion amount of a ship with conventional steel in which the depth of a pit exceeded 2 mm. Flue-gas desulfurization equipment in a coal-fired power station City of Nagoya Environmental Affairs Bureau Steel pipes for air fin coolers and fin tubes VLCC/TAKAMINE (to which NSGP-1 was first applied) VLCC/TSURUGA (to which NSGP-1 was applied) Aframax tanker Shinsei Maru (to which NSGP-1 and 2 were applied at the same time)

4 Atmospheric corrosion Atmospheric corrosion Nickel-based High Weather-resistant Steel NAW-TEN TM NAW-TEN TM complies with JIS G 3114, with the chemical components excluded. Coating Cycle Extension Steel CORSPACE TM CORSPACE TM complies with JIS G 311, JIS G 316 and JIS G 314. Although the use of weather-resistant steel compliant with JIS (JISG3114) is desired, the Specifications for Highway Bridges, the Design Standard of Railway Structures, etc. (hereafter referred to as the regulations ) do not apply to the installation environment. Displays superior weather resistance without coating even when installing the structure in an area not applicable to the regulations regarding weather -resistant steel compliant with JIS. The use with no coating is possible leading to LCC and VOC reductions. Rusting from coating pinholes, deteriorated parts, etc. Rusting from the sharply angled part of a member In an environment in which salt damage is severe, extending the coating replacement period can lead to the reduction of maintenance cost and environmental load. Corroding bridge (in an environment with severe salt injury) Peel-off of bridge coating (in an environment with severe salt injury) Actual application to bridges using nickel-based high weather-resistant steel As of the end of December 216: Accumulating total approx. 31, tons has been applied. Rusting mechanism control principle by alkalinizing the base steel interface Na + Na + Na + Na + Na + Na+ Steel Hydrochloric acid interface () Na + Rust on the outer layer Rust adhering tightly Na +Na+ Na to the inner layer Abnormal corrosion Steel weight 2,ton Number of bridges : 1 : 2 : 3 : 4 : 5 : 61 : 1 NAW-TEN TM has been applied to road bridges and railway bridges not applicable to the regulations of weather-resistant steel compliant with JIS. Na+ + Na+ Na + Na +Na+ Steel Becoming an alkaline interface (NAW-TEN) Rust has a two-layer structure; If the inner layer rust is stable and solid, the progress of corrosion is inhibited. : CI - becomes hydrochloric acid, causing abnormal corrosion. NAW-TEN: Na + becomes sodium hydrate, which is alkaline. Exhibits superior weather resistance without coating even in an environment not applicable to the regulation of weather-resistant steel compliant with JIS. (Applicable environment assessment is necessary.) Two types of steel that can be selected in accordance with the application environment and required performance are offered. (They comply with JIS with the components excluded.) Lineup of products with tensile strength of 4 6 kg Welding materials and high-tension bolts for exclusive use are also included in the lineup Comparable workability with that of conventional steel There are abundant application cases for about 2. Prediction of the corrosion loss amount is possible using the YOSOKU TM software. Ichimura Prize in Industry for Distinguished Achievement (FY1999) Excellence Prize of Monozukuri Nippon Grand Award (FY29) Tanaka Award in Excellence in Research Paper of the Japan Society of Civil Engineers Award (FY25) We offer products necessary for applicability evaluation technology and construction of steel structures. Small-scale exposure test results Corrosion loss amount (mm) Weather-resistant steel compliant with JIS NAW-TEN15 (3% nickel high weather-resistant steel) Exposure duration () Concept of CORSPACE application to a bridge of Japan.5 mdd Weather-resistant steel compliant with JIS (uncoated) Ni-base high weather-resistant steel (uncoated) 1 to 2 km from the coastline CORSPACE (coated) Coastline Exhibits effect in coastal areas with severe salt injury. Corrosion resistance (assessment through an acceleration test [SAE J2334 test]) 6 Peel-off area (mm 2 ) Amount of incoming air-borne salt Fe Fe-.2Sn Amount of incoming >.5 mdd air-borne salt Number of cycles Sea Advantages on order receipt, designing and manufacturing We can assist with the use of the NETIS registered technology (KK-1556-A, registered in February 216) and in making technical proposals and construction performance rating. Cited as tin-added steel in Materials Used of the Bridge Structure Design/ Construction Guidelines issued by the Metropolitan Expressway Company Limited in June 215. Complies with all JIS regarding steel products that are mainly used for bridges. The steel plate manufacturable range is also equivalent to that of conventional steel. Workability in cutting, bending, welding, etc., is comparable with those of conventional steel. Welding materials and bolts for exclusive use are offered. Provides point addition factors in assessment after completion when making proposals. Concept of life-cycle cost reduction * Cost (1, yen/ton) * Extra amount added in accordance with steel material standards + initial coating + repainting 13 Second coating CORSPACE 34 First repainting 54 Extra amount added in accordance with steel material standards First repainting Lapse of time () New Technology Information System of the Ministry of Land, Infrastructure and Transport Third coating 52 Calculation conditions (1) Multiple main girders using steel plates = 16 m 2 /ton (2) Coating conditions: Heavy-Duty Anticorrosion Coating (compiled by the Japanese Society of Steel Construction) CI - detrimental to the formation of protective rust has concentrated in the outer layer rust. The corrosion loss amount is reduced by over 3% of that when using weather-resistant steel compliant with JIS. The peel-off area of the flawed part is small; and corrosion is suppressed. Life-cycle cost can be reduced. Repainting frequency is reduced to once per 1. Hokuriku Shinkansen Hokurikudo Overbridge (Niigata Prefecture) Ohama Grand Bridge (Oita Prefecture) Shimane Museum of Ancient Izumo (Shimane Prefecture) Hanshin Expressway Sambo Junction Higashiharima Nanboku Road (Mizuashi Shintsuji No. 5 Elevated Bridge) Unloader

5 Atmospheric and aqueous corrosion Seawater corrosion Low-alloy Corrosion-resistant Steel Close to Stainless Steel ARU-TEN TM The mechanical are equivalent to JIS G 316 SM49. Seawater Corrosion Resistant (Undersea) Steel MARILOY TM The mechanical are equivalent to JIS G 316 SM4 and SM49. There has been no corrosion-resistant steel that balances corrosion resistance and economic efficiency in a mild indoor environment. Exhibits red rust resistance close to that of stainless steel in a mild indoor environment. Corrosion in a seawater immersion environment. Exhibits superior corrosion resistance to that of conventional steel in a seawater immersion environment. Red rust caused by contamination from human hands indoors Corrosion in a water ballast pipe Positions to which ARU-TEN was applied Positions to which MARILOY was applied Suppresses red rust without coating in an indoor environment. (The use in outdoor environments is enabled by applying a zinc-rich primer.) The total amount of alloy addition (Ni, Cr, etc.) is approx. 1/4 that of SUS34. Comparable yield strength with that of SM49. Machining close to that of SS4. Comparable magnetizability with that of conventional steel. Comparable weldability with that of conventional steel. The corrosion rate in seawater is approx. one half that of conventional steel. The mechanical are comparable with those of 4 49 MPa carbon steels. The weldability is comparable with that of 4 49 MPa carbon steels. Can be used in an indoor environment as an alternative to stainless steel. Has corrosion resistance close to that of stainless steel and workability close to that of conventional steel. Suitable for steel structures used in seawater immersion environments. Exhibits superior corrosion resistance in a seawater immersion environment. Appearances of test pieces after a dry-wet-cycle test Excellent corrosion resistance has been confirmed through a dry-wet-cycle test assuming a general indoor environment. Test conditions: 25 C 5%RH for one hour Transition for.5 hours 5 C 9%RH for one hour Transition for.5 hour The process cycle was repeated 1,12 times (for 14 days). Surface treatment Equivalent to #6 grinding ARU-TEN Excellent corrosion resistance has been confirmed through a dry-wet-cycle test. 5mm Effects A promising new corrosion-resistant steel that balances corrosion resistance and economic efficiency without coating in a mild indoor environment. Corrosion resistance Economic efficiency Mechanical Workability Physical Item Without coating indoors Alloy amount Yield strength (MPa) Tensile strength (MPa) Gas cutting Machinability Weldability Magnetic SS Present Steel type SUS (Plasma) None ARU-TEN (Plasma) Present A corrosion-resistant steel with similar to that of stainless steel designed considering the economic efficiency. Seawater immersion test result Excellent corrosion resistance has been confirmed through a seawater immersion test conducted in an area of Setouchi for three. Corrosion amount (mm) (one surface) MARILOY S49 SS Distance from the top edge of the test piece (mm) (one surface) Excellent corrosion resistance has been confirmed through a seawater immersion test. Corrosion amount measurement result for a seawater gas cooler piping The results of application to the gas cooler tube of a heat exchanger have shown a corrosion rate of approx. one half that of conventional steel. Corrosion amount (mm) Seawater outlet side After 24 months A B C D E F G H I J K Cooling chamber MARILOY S4 SS4 Seawater temperature The effect has been confirmed with actual structures to which MARILOY was applied Seawater inlet side Seawater temperature ( C) Vacuum container (uncoated) Indoor nameplate (uncoated) Pulverized fine coal injection equipment (with a zinc-rich primer) Cargo oil pipes of crude oil tankers Cargo oil pipes Floodgate

6 Atmospheric corrosion High Weather-resistant Steel Vintage COR-TEN A Casting of COR-TEN COR-TEN TM COR-TEN TM is equivalent to SMA4W to 57W for JIS G 3114, and SPA-H for JIS G Atmospheric corrosion VINCOR TM CORQ TM Beauty of Rust appearance change across the ages Corrosion amount.25 One-surface average corrosion amount (mm) requires coating to prevent corrosion, leading to the heavy burden of repainting and other maintenance and management costs. The use of steel in harmony with nature is desired. Shimane Museum of Ancient Izumo COR-TEN meets needs considering the scenery and for other aesthetic purposes Exposure test period (year) The corrosion amount can be reduced more than that of conventional steel. COR-TEN The use without coating is allowed, which reduces repainting and other maintenance and management costs. The esthetic effect can be expected from the soft color of rust ( Beauty of Rust ). Daigo Fukuryu Maru Exhibition Hall COR-TEN is a registered trademark owned by United States Steel Corp. COR-TEN is used without coating (including that of rust stabilization auxiliary treatment) to exhibit excellent weather resistance. The change of surface colors across the ages can be enjoyed. Coating is also possible in the same way as conventional steel. A repainting cost reduction can be expected by extending the cycle of repainting. The weldability and workability are comparable with those of conventional steel. Joining materials (welding materials and bolts) for exclusive use are also offered. Otani Art Museum Prize (FY211) This weather-resistant steel has overcome rust as the biggest weakness of steel in a unique manner using rust to prevent rust. Styling with uncoated COR-TEN Example of corrosion loss amount and surface color change across the ages 1 CORQ is a registered trademark owned by Kyoji Takubo and NSSMC. VINCOR VINCOR is prepared by rendering COR-TEN aged before shipping to give it a special initial color. VINCOR is sold by Chikumakozai Co., Ltd. (TEL: ). CORQ is a casting with the features of COR-TEN. Mainly used as a floor material. CORQ is manufactured and sold by Okayama Casting Center Cooperative Association (TEL: ). The soft color of the protective rust and the change across the ages provide the appearance with an excellent effect. Concept of VINCOR Positions to which CORQ is applied 1969: At the time of completion 1973: After a lapse of four 21: After a lapse of 41 There are many socially important structures and buildings to which COR-TEN has been effectively applied. Corrosion loss amount (mm) By using the index numbers that have a high correlation with colors, the color tone is quantified and reproduced. 35 Index showing the color tone Five 1 Two Lapse of time () months months 6 months The use of COR-TEN is desired indoors. There is a concern about initial rust in the shape of a flow or stream. The use of COR-TEN for floor material, etc. is desired for styling purposes. Discoloration due to rust in the shape of a flow or stream COR-TEN 22 Needs considering the scenery and for other aesthetic purposes can be satisfied Lapse of time () The quantification of colors enables customers to select the color tone of the product at shipping. CORQ COR-TEN in the aged state is provided. Castings are provided for floor materials, etc. A new form of COR-TEN produced from customers needs is proposed. Example of a general floor material (granite flagstones) Parts made of CORQ Expands the possibilities as a floor material used for styling purposes. Used without coating/treatment Used with rust stabilization auxiliary treatment Used with coating Entrance of a restaurant Exhibition in 216 at the Tokyo Metropolitan Art Museum Iiyama Church of the Resurrection